Page 1 COMBINED SERVICE MANUAL G660 Lot 125 Only 86801013 July, 2002 GRADALL 406 Mill Avenue, S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
Page 3 UPPERSTRUCTURE OPERATOR’S MANUAL G660 Lot 125 Only 86801012 July, 2002 GRADALL 406 Mill Avenue, S.W. New Philadelphia, OH, 44663, USA Telephone: (330) 339-2211 Fax: (330) 339-3579...
Page 6: Important Safety Notice
Safe operation depends on reliable equipment and the use of proper operating procedures. Performing the checks and services described in this manual will help to keep your Gradall in reliable condition and use of the recommended operating procedures can help you avoid unsafe practices. Because some procedures may be new to even the experienced operator we recommend that this manual be read, understood and followed by all who operate the Gradall.
Page 7 A FEW WORDS TO THE OPERATOR This manual provides important information to familiarize you with safe operating and maintenance procedures for the Gradall. Even though you may be familiar with similar equipment you MUST read and understand this manual before operating the unit.
Page 9 SAFETY before operating and before engine startup. Inspect your machine daily Do not until all faulty conditions have been corrected. operate the machine up on the Always use two hands when climbing machine. Be sure your shoes are clean and dry. Develop safe and clean working habits.
Page 10 Safety Keep swing area free of tools, buckets and blocking. To prevent slipping, keep deck and cab area free of oil and trash. Always use caution when working near people. Never pass the boom or bucket over people. Never operate the machine with someone standing anywhere on the upperstructure cept in the cab.
Page 11 Be sure you have enough clearance for upper- structure tail swing, especially if there are cars or people in the area. Always have a flagman to direct traffic. On truck-mounted Gradalls, watch out for the carrier cab when swinging the boom. Keep the boom high, and if possible, do not swing close to the cab.
Page 12 Safety Before disconnecting any oil lines, place the boom on the ground or in the boom rest and shut off the engine. Move the control levers and pedals to relieve pressures within the cylinders. Anchor boom using heavy timber or chain. Use extreme caution when high voltage wires are in the area.
Page 13 When parking or traveling with boom in cradle, to prevent allow sufficient clearance damage to cab or windows in case bucket were to close. Be especially careful when operating carrier in remote control: never assume a clear path. Recommended overnight parking precautions include: •...
Page 14 12. Boom Tilt Lever 13. Horn Button 14. Boom Raise & Lower Lever 15. Open Bucket Pedal WARNING 16. Close Bucket Pedal 17. Swing Boom Left Pedal Know and understand controls and instruments 18. Swing Boom Right Pedal before operating the Gradall.
Page 15 CONTROL VARIATIONS (Upperstructure only) CONTROLS COMMON TO CRAWLER CONTROLS COMMON TO SELF-PROPELLED MOUNTED UNITS UNITS AND UNITS EQUIPPED FOR REMOTE CONTROL CONTROLS COMMON TO UNITS EQUIPPED CONTROLS COMMON TO UNITS EQUIPPED WITH DETROIT DIESEL MODEL 4-53 ENGINE WITH DETROIT DIESEL MODEL 4-71N ENGINE...
Page 16 (To be performed at beginning of each work shift) WARNING Use extreme caution when checking items beyond your normal reach. WARNING Any defects or deficiencies noted must be corrected before the Gradall is placed in service. Check entire unit for any evidence of damage or tampering.
Page 17 Check filter indicators at top of filter elements to Check lubricant level in swing transmission and fill determine condition of filters. Replace filters as to level as necessary. necessary. Check hydraulic reservoir breather and clean or Check fluid level in battery and fill as necessary replace as required.
Page 18 Checks and Services Before Starting Upper Engine Check all cab and clean as necessary. windows Cracked or broken windows must be replaced. Check in radiator and fill as coolant level necessary. WARNING If it becomes necessary to check coolant level in hot radiator, turn off engine and relieve pressure before removing cap.
Page 19 Make daily inspections of your Check for crawler. loose bolts, leaky seals and abnormal wear. Report all items needing attention to maintenance personnel for adjustment or repair. If a spark arrester is required by law or jobsite conditions, make sure that one is attached and that it is in good working condition.
Page 20 UPPER ENGINE OPERATION NOTE: If engine is being started at beginning of work shift be sure to perform all “CHECKS AND SERVICES BEFORE STARTING UPPER ENGINE” (pages 10 through 13). Starting Detroit Diesel and Caterpillar Engines (cold start) 1. It is recommended that the engine clutch be 3.
Page 21 Once engine has reached operating temperature run Be alert for unusual noises or vibration. When an at full throttle for efficient Gradall operation. unusual condition is noticed, stop machine in a safe position and shut off engine. Determine cause and correct problem before continuing.
Page 22: Checks After Starting Engine
4. Operate the Gradall slowly through a few com- plete digging cycles to warm the hydraulic oil Install the appropriate bucket or attachment for throughout the system.
Page 23: Bucket Installation
BUCKET INSTALLATION WARNING Keep boom in fully extended position while installing bucket. Stay clear of bucket and boom until bucket adapter has been fitted to bucket as shown in step 3. Position adapter above bucket tube with adapter in Lower boom until bucket tube seats firmly within “Bucket Open”...
Page 24: Remote Control
REMOTE CONTROL NOTE: Remote control is to be used for positioning unit at job site, not for over-the-road travel. Preparing carrier for remote control operation 1. Apply parking brake. WARNING 2. Start carrier engine and develop full brake system Be sure to keep feet clear of clutch pedal when pressure in front and rear portions of system moving DIGGING BRAKE toggle to ON position (125 psi).
Page 25 Precautions for remote control operation Be sure of unobstructed visibility in direction of especially watchful for overhead wires and travel; use a signalman to compensate for blind traffic. spots. Never tow load using remote control drive. Be sure upperstructure swing brake functions Always give audible signal before moving unit.
Page 26 CRAWLER MOUNTED UNITS Use Your Crawler Properly 1. Travel in forward direction whenever possible 5. Rough operation and operation on uneven (with track drive motors at rear). Traveling in ground can cause unnecessary wear and damage reverse increases wear on sprockets. to track components.
Page 27 Crawler Controls Straight Foward Straight Backward Turn Left Turn Right...
Page 28 Always give audible signal before moving unit. Be sure of clear path for carrier, boom and Never tow load with self-propelled Gradall. counterweight before starting to move. Be REMEMBER THAT DIRECTIONS ARE BASED ON UPPERSTRUCTURE OPERATOR FACING IN THE SAME DIRECTION AS THE CARRIER...
Page 29 Transmission Control 1. Be sure that unit is fully stopped and that BRAKES toggle is in the ON position. 2. Move transmission shift lever to the desired speed range position. Transfer Case Control (4 x4 units only) 1. Be sure that unit is fully stopped and that BRAKES toggle is in the ON position.
Page 30 TO MAKE A TYPICAL GRADALL CUT IMPORTANT Your Gradall has sufficient power to permit a fast efficient digging cycle. The procedure on the following pages describes a typical cycle in separate steps; as you gain experience, combine control functions for a smooth cycle with no lost time.
Page 31 Press outer right pedal to swing the boom right , or Push right lever forward to extend boom and at inner right pedal to swing left , out over the the same time push left lever forward to lower boom proposed digging site.
Page 32 To Make A Typical Gradall Cut Position bucket open or closed for correct Pull center lever back to tilt boom clockwise penetration while boom is being lowered. Push push center lever forward to tilt boom counter- forward on left lever to force boom down for clockwise if necessary.
Page 33 Pull right lever back to retract boom , and at the The bucket cutting edge raises as the boom retracts. same time push left lever forward to apply down Slight adjustment of bucket open pedal pressure to maintain grade advisable to maintain grade. NOTE: Depth of cut should depend on hardness of Continue with steps 7 and 8 until bucket is full.
Page 34 To Make A Typical Gradall Cut Pull left lever back and as the boom rises, press When bucket is raised high enough to clear ob- inner left pedal to close the bucket and prevent structions, swing boom left or right to dump excess spillage.
Page 35 Press outer left pedal to open bucket and release Swing boom left or right to align boom for next dirt. cut and repeat steps 4 through 11.
Page 36: Operating Tips
2. When ditch cleaning from the road on a rubber tired carrier truck-mounted Gradall, travel with traffic toward the unclean end of the ditch, for a clear view of the cleaned ditch, the road shoul- der, and the truck hauling the spoil.
Page 37 Emergency Parts Kits If the Gradall is working in remote or hard-to-get-to areas, one of the emergency parts kits available should be kept with the machine. These kits are good insurance against downtime due to minor repairs or replacements.
Page 38: In Case Of Trouble
3. Fill fuel tank to minimize condensation. 6 x 6 carriers is fully explained in the “G-660 GRADALL 6 x 4 and 6 x 6 CARRIERS OPERA- 4. Lock cab and install protective window covers if TOR’S MANUAL.” The following procedure is available.
Page 39: Table Of Contents
LUBRICATION RECOMMENDED LUBRICANTS * Viscosity ASTM: (SSU at 100 F.) Rust Test (ASTM D 665): Pass (Procedure A) Viscosity #215: (ASTM D 88) 194-235 (Centistokes at 100 F.) Oxidation Test (ASTM D 943): 1000 hr. min. to a Neut No. of 2 (ASTM D 445) 41.9-51.0 (See Notes 4 and 5 ASTM D943) Viscosity Index...
Page 42: Typical Applications
TYPICAL APPLICATIONS...
Page 45: Keep Machine Clean
KEEP MACHINE CLEAN SCHEDULED MAINTENANCE What is Scheduled Maintenance for GRADALL? It is the day-by-day care of small details on your machine - all according to a regular plan. Scheduled Maintenance keeps your GRADALL in steady production. It extends the life of your machine over more productive years, and helps keep your machine in efficient condition.
Page 46 Operating ore Operating Chec Chec These P oints Bef ore Operating the Gradall Upperstructure! the Gradall Upperstructure! the Gradall Upperstructure! the Gradall Upperstructure! the Gradall Upperstructure! 2. Inspect air cleaner indicator. 1. Fill engine radiator with water 3. Check oil level. If oil level, add to Replace if filter is dirty.
Page 47 GRADALL CHART SCHEDULED MAINTENANCE Here is a Typical Gradall Maintenance Program The above schedule is a guide to good scheduled maintenance. However,frequency of checking and lubricating may have to be increased under certain conditions. Also, additional points may need attention. Some Gradalls are equipped with optional acces sories.
Page 48 GRADALL SCHEDULED MAINTENANCE DAILY Check oil level and filter dirt indicator. Hydraulic Oil WEEKLY Clean magnet. and Reservoir Replace gasket and clean tank. Drain off sample YEARLY and check for water in oil. The hydraulic to reduce contamination. Seasonal changes maybe required.
Page 49: Swing Transmission
GRADALL RECOMMENDATION SCHEDULED MAINTENANCE WEEKLY Inspect rod packing for excessive leakage. Cylinders MONTLY Check cylinders for oil by-pass. YEARLY Rebuild all cylinders installing new piston rings and wipers. Examine cylinder Pins and Bushings. Boom and Tilt Rollers WEEKLY Inspect boom roller adjustment.
Page 50: Hydraulic Fluid
HYDRAULIC FLUID The wrong hydraulic oil will cause serious trouble. Hydraulic oil quality and cleanliness directly influence the overall efficiency of the Gradall. The oil flowing through the highly sensitive elements of the hydraulic system must be absolutely clean. Here are some instances where action is required to prevent serious trouble: 1.
Page 51 BOLT MARKING & TORQUE CHARTS Special torques may be shown on the Parts Page. IMPORTANT: Be certain you know the following information about the bolt you are tightening, otherwise you may cause serious damage to the bolt: Some of the more important bolts that need torquing: a.
Page 52 GRADALL SCHEDULED MAINTENANCE...
Page 53: Hydraulic System Operation
GRADALL HYDRAULIC SYSTEM OPERATION Four hydraulic cylinders and two hydraulic motors operate the five actions of the Gradall. Each circuit operates an follows: Boom In-Out Circuit one cylinder; G-660, 12 foot stroke; G-880, 13 foot stroke. Boom Hoist Circuit two cylinders; can go up to 30° down 90°.
Page 54 PUMP The Gradall upperstructure is powered by a Diesel Engine The oil which is used to provide Gradall’s movements is operating at the RPM necessary to turn the hydraulic pumps propelled by a gear type pump with three sections, mounted at their rated speed.
Page 55: Hydraulic Oil Filters
GRADALL HYDRAULIC SYSTEM OPERATION RESERVOIR The reservoir holds the supply of hydraulic oil. It helps to Clean, filtered oil flows from the bottom of the reservoir keep the oil cool. It filters the oil. Entrapped air is dissi- directly into the pumps. Oil is returned to the reservoir, pated.
Page 56 HYDRAULIC SYSTEM OPERATION GRADALL PUMP TO MANIFOLD CIRCUIT Pump Circuits (Standard Machine) Oil from the base pump section is routed to the No. 2 Boom IN-OUT Control Valve. If it is not used, it auto- matically goes back to dump.
Page 57 GRADALL HYDRAULIC SYSTEM OPERATION MANIFOLD Manifold with Relief Valves The Manifold contains the base block. Five identical control Boom down speed control. An adjustable orifice is built into valves; three pump relief valves and six hose relief valves. the Manifold. It meters the amount of oil being exhausted from the top side of the two hoist cylinders.
Page 58: Control Valves
HYDRAULIC SYSTEM OPERATION GRADALL CONTROL VALVES There are five identical control valves mounted underneath Plunger Extended the Manifold. Oil from the control valve is routed to and " movement of the control valve plunger is possible in from each of the five circuits depending upon which control either direction from neutral.
Page 59: Auxiliary Manifold
From here the oil is routed to the Center-Pin and down to equal volume of oil is always supplied to each track. the Carrier Drive Motor. GRADALL G-660 (Lot 57) Hydraulic Remote Control Circuit GRADALL G-660 (Lot 57) Crawler Circuit Gradall G-660 (Lot 57) Crawler Circuit...
Page 60 HYDRAULIC SYSTEM OPERATION GRADALL LOCATION OF CARRY OVER PLUGS, DIVERSION PLUGS AND CAPS Carry Over Plugs Neutral dump oil is routed to another circuit by using Carry Over Plugs which are installed in the top side of the Main Manifold and the Auxiliary Manifold. These Carry Over Plugs are used in the standard, hydraulic remote and crawler models.
Page 61: Control Linkage
GRADALL HYDRAULIC SYSTEM OPERATION CONTROL LINKAGE The Gradall Upper is operated by three hand levers and two pairs of foot pedals. The hand levers are used for the Boom IN-OUT, TILT AND HOIST. The foot pedals are used for TOOL AND SWING.
Page 62: Tilt Gear Box
HYDRAULIC SYSTEM OPERATION GRADALL PUMP RELIEF VALVES HOSE RELIEF VALVES The Tool, Hoist and Boom Circuits each receive oil directly Since it is possible to utilize more than one machine action from the pump. The Manifold is ported to give access to at a time, hose relief valves are provided to prevent exces- pump relief valves from each of these circuits.
Page 63: Swing Bearing
GRADALL HYDRAULIC SYSTEM OPERATION Swing Circuit SWING CIRCUIT SWING BEARING The sketch illustrates the swing circuit. Oil is supplied to this The upperstructure rotates on a sealed ball bearing assem- circuit from the end pump section. It’s operating pressure is bly.
Page 64: Tool Circuit
HYDRAULIC SYSTEM OPERATION GRADALL HOIST & TOOL CYLINDERS BOOM IN-OUT CYLINDER The Hoist and Tool Cylinders are simple double-acting The Boom IN-OUT Cylinder is also a double-acting cylin- cylinders with oil applied to each side of the piston. der, but of a more complex design. Oil for both sides of the piston is fed into the cylinder through the boom cylinder gland at the rear end of the piston rod.
Page 65: Hoist Circuit
GRADALL HYDRAULIC SYSTEM OPERATION HOIST CIRCUIT Oil for the Hoist Cylinders is routed from the No. 4 Hoist Control Valve to the bottom and top ends of the Hoist Cylinders. Extending the cylinders lowers the boom and retracting the cylinders raises the boom. To control the speed...
Page 66 HYDRAULIC SYSTEM OPERATION GRADALL BOOM IN-OUT CIRCUIT Boom In-Out Cylinder Circuit Oil for the Boom IN-OUT Circuit comes from the No. 2 Control Valve. Oil goes from the Control Valve to the Boom Cylinder Gland at the rear of the piston rod.
Page 67 GRADALL HYDRAULIC SYSTEM OPERATION HEAT EXCHANGER CIRCUIT A heat exchanger circuit is used on the Gradall to help con- If pressure builds in excess of 50 psi at the heat exchanger trol the temperature of the hydraulic oil. valve, a plunger opens and allows the excess oil to pass through the filter units into the reservoir.
Page 68 HYDRAULIC SYSTEM OPERATION GRADALL CENTER PIN (for Crawler & Remote) For Crawler and Remote Control Models there is a Center Pin. It is used to carry oil from the upperstruc- ture to the undercarriage and back. It is located in the center of the upperstructure underneath the cradle.
Page 69 WARNER & SWASEY SWING FLOW VALVE HYDRAULIC SYSTEM OPERATION This leaflet describes the operation of the Swing Flow Valve. Oil enters the Swing Flow Valve from the Pump via a control valve. When the Swing Flow Valve is pressur- ized, the oil leaves for the Swing Motor, and also goes through a small hose to the Swing Parking Brakes, releas- ing it.
Page 70 WARNER &SWASEY SWING FLOW VALVE HYDRAULIC SYSTEM OPERATION When the equipment is operating, the hydraulic oil reaches high temperatures. If valves are to be removed immediately after machine has been operating, exercise extreme caution when disconnecting hydraulic hoses or han- dling the valve.
Page 71: Top View
WARNER &SWASEY SWING FLOW VALVE HYDRAULIC SYSTEM OPERATION Fig. 5 The operator steps on one of the swing pedals (in the cab) and the oil is routed from the control valve to the Swing Flow Valve. Pressure is built-up and moves the lock-out plunger to one side.
Page 72: Right Side View
WARNER &SWASEY SWING FLOW VALVE HYDRAULIC SYSTEM OPERATION Fig. 6A Oil flow upseats the check plunger and continues back- ward to the horizontal flow chamber. Two test ports are provided to measure pressures while swing action is stalled. RIGHT SIDE VIEW Fig.
Page 75: Control Levers
COLD OIL. reduced depending upon the degree of internal wear. Testing pumps with Flow Meter. CONTROL LEVERS The Gradall is operated and tested by the movement of hand control levers and foot pedals to actuate the respec- PUMPS tive valve plunger.
Page 76 Refer to the specification page at rear of this section to find the pressure each Pump Relief Valve should open. Gradall’s power is determined by the ability of the IMPORTANT: Do not use the Swing action to test pumps to put forth required pressure. Pump Relief Valves the No.
Page 77 GRADALL G-660 (Starting Lot 57) CONTROL VALVES AND MANIFOLD TESTING HYDRAULIC SYSTEM Remove capscrew (A). With a small screw driver, adjust the needle valve. This valve restricts the flow of oil from the top sides of the hoist cylinders to control the fall of the boom.
Page 78 GRADALL G-660 (Starting Lot 57) TESTING PUMP RELIEF VALVES TESTING HYDRAULIC SYSTEM HOW TO TEST PUMP RELIEF VALVES 1. Clean test port area, and place gage in test port. 4. Take a gage reading. Valve No. 2 should read 1350 psi.
Page 79 GRADALL G-660 (Starting Lot 57) TESTING HOSE RELIEF VALVES TESTING HYDRAULIC SYSTEM HOSE RELIEF VALVES HOW TO TEST HOSE RELIEF VALVES For protection of the hoses, and as a safety device. Hose For convenience, all Hose Relief Valves should be Relief Valves are installed between the control valve and tested in the tool circuit location above the No.
Page 80 SWING FLOW VALVE GRADALL G-660 (Starting Lot 57) TESTING HYDRAULIC SYSTEM HYDRAULIC MOTORS HOW TO TEST THE SWING FLOW VALVE 1. Test the Swing Pump Relief Valve using the Boom Tilt or Tool action (see page 4). 2. Set it at 2000 psi (see section on Hydraulic Adjust- ments, look under “How to Adjust the Pump Relief...
Page 81 GRADALL G-660 (Starting Lot 57) HYDRAULIC CYLINDERS TESTING HYDRAULIC SYSTEM HOW TO TEST CYLINDER EFFICIENCY (BY-PASS TEST) HOW TO TEST CYLINDER EFFICIENCY (BY-PASS TEST) One of the easiest tests is to observe the amount of oil TOOL CYLINDER being forced past the piston rings inside the cylinder. The amount of oil which flows indicates the condition of the cylinder.
Page 82: Hydraulic Pressures
GRADALL G-660 (Starting Lot 57) HYDRAULIC PRESSURES TESTING HYDRAULIC SYSTEM Engine R.P.M. (Full Load) ....2400 (With two Pump sections bottomed, 52, 26 G.P.M.) Hydraulic Pressures** ALL RELIEF VALVES ARE...
Page 83 GRADALL HYDRAULIC ADJUSTMENT RELIEF VALVES HOW TO ADJUST THE PUMPS HOW TO ADJUST THE PUMP RELIEF VALVES Place gage in test port. If tests show that the pump is not putting out Loosen Valve Retainer care- required pressure volume pump fully.
Page 84 GRADALL HYDRAULIC CYLINDERS HYDRAULIC ADJUSTMENTS HOW TO OVERHAUL A HOSE RELIEF VALVE If test gage indicates the Hose Relief Valve cannot adjusted, remove valve quickly and plug the hole. Disassembly valve. Inspect valve body check condition seat. worn unevenly, replace entire assembly.
Page 85 GRADALL TOOL AND HOIST CYLINDERS HYDRAULIC ADJUSTMENTS HOW TO REMOVE THE TOOL CYLINDER Remove bucket adapter tool bolts Remove bucket from boom. Remove front tool cylinder linkage pin. Place plank under cylinder ease handling. Extend tool cylinder rod until the piston...
Page 86: Boom Cylinder
GRADALL BOOM CYLINDER HYDRAULIC ADJUSTMENTS BOOM CYLINDER REPACKING Replacing piston rings, packing,”O” Replace piston rings. rings, etc., in the boom cylinder, can be done Using Come-Alongs to pull the telescopic inside boom. Because height boom back, center barrel over piston the machine, a platform area such as a loading rings.
Page 87: Hydraulic Cylinders
HYDRAULIC CYLINDERS HYDRAULIC ADJUSTMENTS CYLINDER OVERHAUL The hydraulic cylinders on the Gradall are all WORKING cylinders. They are not classed as strictly positioning cylin- ders. As such, they must be kept in top notch condition at all times in order to have the machine working efficiently.
Page 88 HYDRAULIC CYLINDERS HYDRAULIC ADJUSTMENTS Using a pry bar, force the held casting out of the cylinder bar- Pull the head, rod and piston assembly from the barrel. On a rel. Be careful so that you do not damage the inner surface of the bar- well worn cylinder this can be done by hand.
Page 89 HYDRAULIC CYLINDERS HYDRAULIC ADJUSTMENTS Make sure that a new O Ring is placed in position under the Fit the individual places of rod packing into the head. The piston as it is fitted to the rod. Secure the box castle nut or stake gland* can be used as a ram to help position each place.
Page 90: Cylinder Reassembly
HYDRAULIC CYLINDERS HYDRAULIC ADJUSTMENTS Install new barrel and rod bushings. The repacked cylinder is now ready for installation on the machine. If time cylinder is to be stored for any period before being used, it it good to remove the plugs and fill the barrel with clean hydraulic oil.
Page 91: How To Adjust The Clutch
Release button and replace cover. perform only as well as the output of these engines. The Gradall engine turns at 2400 RPM (Full load). If qualified engine mechanics are not in your employ- ment, contact the local engine distributor for service assistance.
Page 92 2. Loosen bolts on either side of adjusting screw. 3. Add or remove shims and turn adjusting screw until The Gradall Telescopic Boom rides on four concave roller is in proper position. and four flat rollers. The rear end of the telescopic boom 4.
Page 93: Bearing Adjustment
GRADALL BEARING ADJUSTMENT MECHANICAL ADJUSTMENTS SWING BRAKE ADJUSTMENT 8. Adjust Orifice Valve, as desired, to govern brake setting speed. 1. Loosen Jam Nut A. NOTE: Keep linkage and exposed moving parts well lubricated with oil. 2. Back off Adjusting Screw B.
Page 94 GRADALL TILT and SWING TRANSMISSION MECHANICAL ADJUSTMENTS TILT GEAR BOX Within the Tilt Gear Box there are six bearings on For ease of adjustment of the final pinion shaft, weld three shafts. These bearings can be adjusted by use of an eye to a small plate.
Page 95: Roller Adjustment
GRADALL TILT CIRCLE ROLLER ADJUSTMENTS MECHANICAL ADJUSTMENTS MAIN BOOM TILT ROLLER ADJUSTMENT The main boom assembly tilts within the boom cradle Use the following steps to make the tilt roller adjust- 90° in either direction from level. The boom is centered ment: on four rollers.
Page 96 GRADALL TILT CIRCLE ROLLER ADJUSTMENTS MECHANICAL ADJUSTMENTS 5. After adjusting gears, bring the two bottom rollers in 9. With the boom level, adjust the two top tilt rollers in until they make contact with the tilt circle. Lock the towards the tilt ring until a light contact is made.
Page 97 GRADALL BOOM ROLLER ADJUSTMENT The Gradall telescopic boom rides on eight rollers (16 on G-1000 Gradalls). Five rollers are attached to the front of the main boom consisting of four flat (two each on the bottom and side) and one concave at the top. Three concave rollers are attached to the rear of the telescope boom.
Page 98 Study these instructions, always making sure the rollers are locked after final adjustment using: Lockwire for eccentric shaft. 200 Ft. Lbs. torque on locking bolts on the shim style. Extend telescope boom so that the rear roller brackets are in the center of the second front hole of the main boom.
Page 99 Center the front of the telescope boom by Square booms up (bottoms parallel) by adjusting the side flat rollers of the main boom adjusting the bottom flat rollers of the main leaving 1/16" clearance to a side. boom. Center the rear inside of the telescope boom by Adjust outside top concave roller to the adjusting either the inside right or left concave telescope boom leaving approximately 1/32"...
Page 100 GRADALL BOOM ROLLER ADJUSTMENT- SHIM STYLE TO ADJUST SHIM STYLE ROLLERS FOLLOW THESE FOUR STEPS: ADJUSTING BOLT LOCKING BOLT FLAT WASHER 14 PER MACHINE 32 PER MACHINE 4 PER MACHINE SHIMS Back off both locking bolts (A) Tighten and/or loosen adjusting bolt (B) to move the roller bracket assembly to the correct center line location.
Page 101 SHIM LOCATIONS WHEN CHECKING ROLLER ADJUSTMENT, LOOK FOR THE FOLLOWING: EXCESSIVE CLEARANCE . . . which causes pounding and shock loading. This in turn will damage bearings, bend roller brackets, collapse boom tubes, etc. POOR ALIGNMENT . . . which will chip or bend the lips of the rollers;...
Page 102 TYPICAL EXAMPLE: SHIM STYLE ROLLER ADJUSTMENT MAJOR AREA’S OF WEAR CHECKING BOOM ROLLER ADJUSTMENT Hang a trouble light inside the main boom Spray paint on boom tubes after adjustment. behind the telescope boom roller to be checked. Run boom in and out a few times and observe Visually check the roller from the front of the roller contact from the witness lines left on the boom.
Page 103 GRADALL BOOM ROLLER ADJUSTMENT-ECCENTRIC STYLE TYPICAL SINGLE ROLLER ASSEMBLY The end of each front eccentric shaft is splined to match a serrated washer. The washer is used to lock the shaft. The washer has a flat side which butts against a stop block to keep it from turning. A cap screw holds it to the shaft.
Page 105 BOOM CYLINDER ADJUSTMENT After you adjust the boom rollers, take a few extra minutes to double check the alignment and adjustment of the components around the boom in-out cylinder. The act of adjusting the rollers will alter other tolerances because you may have changed the relative positions or spacing between the two booms and the cylinder.
Page 107 GRADALL INSIDE HOSE TROUGH TOOL CIRCUIT ADJUSTMENT MECHANICAL ADJUSTMENTS FORM No. 0003...
Page 109: Troubleshooting
TROUBLE SHOOTING CHART TROUBLE SHOOTING If your Gradall is not working right, attempt to isolate the trouble. If a problem is in one circuit only, stay within that circuit and test individual components. A problem that is common to all circuits is likely to be caused by the engine, clutch, reservoir, oil, or pump.
Page 110 GRADALL TROUBLE SHOOTING CHART TROUBLE SHOOTING - Continued REMEDY PROBABLE CAUSE PROBLEM TOO FAST SWING Cushion Valve pressure set Inspect and adjust STOPPING ACTION too high ....
Page 115 GRADALL * HOPTO * CRANE GENERAL HYDRAULIC SYSTEM FLUID SYSTEM LEAKAGE SAE STRAIGHT THREAD “O” RING SEAL SAE 37° FLARE CONNECTION CAUSES: 1. Elbows loosen up after short service. 2. “O” ring leakage after short service. 3. “O” ring leakage after long service.
Page 116 GRADALL * HOPTO * CRANE HYDRAULIC SYSTEM GENERAL SAE 4-BOLT SPLIT FLANGE CONNECTION cure: Lubricate the “O” ring before assembly. All matting how it works: surfaces must be clean. All bolts must be evenly The SAE 4-bolt split flange connection torqued.
Page 122 CRAWLER INTRODUCTION The following pages have been prepared to provide some basic theory regarding crawler application and some background information on the areas of service that will show up on machines. As a general rule, the crawler undercarriage of a machine will cost the owner as much or more for periodic main- tenance and overhaul than the upperstructure.
Page 123 CRAWLER NOMENCLATURE Warner & Swasey Hydraulic Excavators are mounted on as to prevent all of the rollers from hitting the seams in tractor type undercarriages, although they differ in many the chain at the same time. ways from a standard crawler tractor. 3.
Page 124 CRAWLER TRACK SHOE SELECTION MINIMIZE OVERHANG LOW PROFILE GROUSERS Select the low profile grousers if possible. The single Some owners carry spare shoes to replace those which grouser shoe will penetrate the ground deeper and turning have become bent. They then take the bent ones to the may become difficult to impossible without extra maneu- shop for straightening and future use as spares.
Page 125 CRAWLER CRAWLER WEAR Always utilize power to both tracks when turning by apply- 5. Plan your work so that your turns to right or left are as ing hydraulic motor power to both tracks at the same time. even as possible. Constant turning in one direction will If you use power to one track only, you will be dragging wear one track faster than the other.
Page 126: Track Adjustment
CRAWLER CRAWLER WEAR The following represents a discussion of the various areas of the crawler undercarriage where periodic inspection and corrective action can make your machine more productive with less down time: TRACK SHOE BOLT TORQUE Experience has proven that it is important to fasten the track shoes to the chain using a torque wrench and apply- ing the torque as follows;...
Page 127: Chain Wear
CRAWLER TRACK ADJUSTMENTS TRACKS TOO TIGHT If a track is adjusted too tight, a great amount of friction Severely tight track adjustment can cause the track to run will exist between the pins and bushings when the track extremely hot and “draw-back” the hardness of pins and links hinge as they travel around the sprocket and idler.
Page 128: Change Master Pin
CRAWLER CHAIN WEAR Since wear takes place on only one side of the pin and since wear takes place on only the sprocket side of the bushing, it is common practice to rotate the pins and bushings one time before replacing them. Therefore, let's take a set of tracks that would normally be good for 2000 hours.
Page 129 CRAWLER CHAIN WEAR Allowing pins and bushings to be run to destruction will result in accelerated wear to all the track components. The space resulting from internal pin and bushing wear permits the bushings to cock relative to the pins, allowing the track to wander from side to side.
Page 130 CRAWLER CHAIN WEAR There are three basic guides to determine when pins and bushings should be turned. They are: 1. When the (current) wear line on the drive side of the sprocket teeth approaches 1/4" of the tips (if this is not the first set of bushings used with this sprocket or if the bushings have been turned previously, a second wear line may be apparent).
Page 131 CRAWLER SPROCKETS The wear on sprocket teeth caused by increased track pitch is just one of the many types of sprocket wear. The various types of wear can be identified by careful inspection of the sprocket teeth and noting the location of the wear.
Page 132 CRAWLER TRACK ROLLERS Wear to the track rollers on your machine will vary depending on the ground conditions and the operator's work habits. Periodic examination of the individual rollers will tell you the amount of wear on each. Watch for red oil on a lower roller or track. (The oil is dyed red so that leaks can easily be spotted.) Find the leaking component and install new seals.
Page 133 12CRAWLER ROLLER FRAME ALIGNMENT ROLLER FRAME ALIGNMENT It is of extreme importance that the track rollers, the idler tumblers, and drive tumbler be kept in good parallel alignment. Check roller frame alignment carefully when adjusting tracks or when parts are installed. Roller frames must be parallel.
Page 134 CRAWLER TRACK GUIDING GUARDS TRACK GUIDING GUARDS WHEN a machine is working in rock, one of the most use- share of the load, without having to climb the sides of ful items of track equipment is the track guiding guards. improperly aligned track.
Page 135 CRAWLER INSPECTION GUIDE Wear takes place in your crawler undercarriage not only when the machine is actually crawling, but even when it is sitting still and the upperstructure is working. To help you determine the time limits for your rebuild, we are providing some vital dimensions. We will provide the dimensions of the new parts and we will tell you just how much wear can take place before rebuild or replacement is needed.
Page 137 PARTS & SERVICE BULLETIN W&S 74-6 No. ____________________________ July 16, 1974 Warner & Swasey Distributors ATTENTION: Service Managers SUBJECT: Crawler Undercarriage Maintenance Gentlemen: We use a tractor-type undercarriage under the various models of Gradalls and Hydraulic Excavators. This design gives us a relatively trouble-free package, requiring less mainte- nance than former designs.
Page 141: Bolt Torque
MECHANICAL ADJUSTMENTS CRAWLER GEAR BOX Keep gear box covers water tight. Inspect sprocket teeth for exces- sive or uneven wear. Repair or Check bolt torque on cover plate replace as needed. every 50 hours. Check for excessive wear on slide pads.
Page 143 Your dealer stocks a selection of kits and Gradall Replacement Parts – let him help you save time and money.
Page 145 H y d r a u l i c E x c a v a t o r s a n d C r a n e s REPAIR PARTS KITS FOR MODEL G-660 GRADALL The Kits shown on this page contains the parts normally required for rebuilding pump and hose relief valves.
Page 147 H y d r a u l i c E x c a v a t o r s a n d C r a n e s REPAIR PARTS KITS FOR MODEL G-660 GRADALL The kits shown on this page contains the parts normally required for rebuilding com- ponents in the control valve area including the control valves, pump and hose relief valves and swing flow valve.
Page 148 REPAIR PARTS KITS FOR MODEL G-660 GRADALL Kit No. 549 Manifold Area “0” Ring Kit for 8668-5004 or 8668-5005 Manifold Assembly Refer Parts pages 22 & 23 8 - 25C-244 “0” Rings 18 - 25C-331 “0” Rings 30 - 25C-375 “0” Rings 7 - 25C-810 “0”...
Page 149 H y d r a u l i c E x c a v a t o r s a n d C r a n e s REPAIR PARTS KITS FOR MODEL G-660 GRADALL The Kits shown on this page contains the parts normally required for rebuilding and maintenance of the tandem pump, tilt motor, swing motor and swing flow valve.
Page 150 REPAIR PARTS KITS FOR MODEL G-660 GRADALL Kit No. 542 Motor Seal Kit for 8664-1038 Tilt & Swing Motors Refer Parts page 10 A 2 - 25G-585 Parts Group B 1 - 50M-238 Seal Strip C 2 - 8664-1043 “O” Rings...
Page 151 Complete list of parts in Kit No. 550 is shown on reverse side of this page. ORDER THESE KITS FROM YOUR LOCAL GRADALL DISTRIBUTOR Be sure to include the serial number of your Gradall when ordering kits or parts . 0098...
Page 152 KIT NO. 550 PARTS LIST GRADALL G-660 Quan. Part No. Description Quan. Part No. Description Kit 307 Repack Kit — Tool 50V-160 Seal Kit 309 Comp. Cyl. Repack Kit 50T-20 “O” Ring Kit 532 Relief Valve Kits 50V-179 Back-Up Ring...
Page 153 The parts contained in Kit No. 551 have been selected on the basis of field usage of the G-660 machine. These are parts that will enable you to take care of the emergency repairs and to obtain top performance of your Gradall the year around.
Page 154 KIT NO. 551 EMERGENCY PARTS AND REPACK KIT FOR THE G-660 GRADALL Qty. Part No. Name Kit #309 Repack Kit Complete Kit #540 Pump Seal Kit 25A-309 Lockwasher 25C-243 “0” Ring 25C-310 Spring 25C-331 “0” Ring 25C-375 “0” Ring 25C-458...

Gradall G660 Combined Service Manual

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